Heliocol SHC-ITS-HC40 User manual

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Contents
1 Introduction .........................................................1
Overview .................................................................1
Conventions used in this Guide ............................ 2
Safety precautions ................................................. 2
2 Basic Heliocol Terminology................................3
3 Designing your system ........................................4
Deciding on the location for the panels..................4
Preparing a schematic diagram ...............................5
Sample collector system ..........................................6
Mounting racks .........................................................7
4 Parts and tools .....................................................8
Heliocol fittings and accessories .............................9
5 Hydraulics...........................................................11
Panel configurations ...............................................11
Guidelines for residential installations ..................11
Basic plumbing & array layouts .............................12
Plumbing ..................................................................13
Balanced flow ...........................................................13
Pump power ..............................................................14
Booster Pumps.............................................................14
Automatic drainage ..................................................15
6 Installation...........................................................16
Connecting panels together .....................................16
Bypassing a small obstruction .................................18
Connecting panels across a large obstruction ........18
7 Connecting to the existing equipment ...........19
Feed and return lines..................................................19
Connecting with the existing filtration system .......20
Plumbing guidelines ..................................................21
Automatic systems (Private & public pools)...........22
8 Operation............................................................24
Turning the system on (manual systems) ................24
Turning the system off (manual systems) ...............24
9 Troubleshooting.................................................25
10 Replacing a damaged riser tube...................27

Page 1
1 Introduction
Heliocol Solar Pool Panels are manufactured utilising state-of-the-art technology and production
techniques. Heliocol collectors are sleek and simple, yet the patented overmoulded design make
them durable to last a lifetime. Correct installation is essential to the overall success of the system.
Installed correctly, a Heliocol System is practically maintenance free, as it taps solar heat year
after year.
This manual contains easy, step-by-step instructions to help ensure that your installation meets our
recommended standards. It also includes techniques and tips gathered from experienced Heliocol
contractors that will save you time and effort.
Overview
Heliocol solar heating systems can be either mounted on a roof or on the ground. In either case the
collectors may lie directly on the mounting surface, or, if a change of angle is necessary, on a
specially constructed rack.
The illustration below is of a typical roof mounted system, highlighting the three basic areas:
1. The solar collectors
2. The existing water filtration system
3. The feed-and-return plumbing that connects between the solar panels and the existing filtration
system.
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Conventions used in this Guide
Table 1: Icons used in this Guide
Important: While this manual explains how to install Heliocol Solar Panels properly in typical
situations, it cannot address all the possible individual cases. If you have any installation questions,
contact your Heliocol representative for assistance. As the installing contractor, you are responsible
for fulfilling top quality standards when installing Heliocol panels.
Safety precautions
Warning: There is no substitute for safety. Do not take short cuts. Always exercise extreme caution,
care and good judgment when working on or around a roof or pool area.
Take care to avoid hazards such as overhead electrical wires or loose tiles.
Do not allow extension cords to trail into the pool or other stagnated water.
Disconnect the power supply to the pool when installing an automatic control system.
When working on a steep roof, use a safety rope.
Be sure to secure ladders so they do not slip or fall.
Wear shoes with good tread to avoid slipping on the ladder or sloping roof areas.
Do not leave materials or equipment on a sloping roof where they could fall off.
When working outdoors in warm weather keep yourself adequately protected from the sun
and make sure to drink regularly.
Important: Avoid treading on Heliocol collectors! Wherever possible, the system should be installed
so that all parts of it are accessible.
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2 Basic Heliocol Terminology
Modules /panels / banks/ arrays
Heliocol collectors are manufactured as individual “modules”, and connected together in the
factory in groups of four modules to form “panels”. You connect the supplied panels together to
form “banks” of various lengths, depending on the individual requirements at your site.
A Heliocol solar heating system consists of one or more banks of collectors, connected to the
swimming pool filtration system.
Panel –4 modules welded
to one another at the factory.
Bank –a system made of several panels joint together with PPC connectors.
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3 Designing your system
This chapter describes the factors you need to take into account when designing your system, and
the process of creating the plan of the system structure.
Important: At all stages of the design and construction keep in mind that you want to produce a
system for the customer that will be as efficient and as aesthetically pleasing as possible.
Deciding on the location for the panels
The first thing to do is determine the location of your solar heating system. The following factors must be
taken into account:
Collector area –The total panel area must be large enough to heat the pool efficiently. The exact
optimum size depends on many factors in addition to the pool surface area, including climate,
latitude, roof orientation and slope, winds, pool covered at night and the presence of local
obstructions (such as overhanging branches) between the panels and the sun.
An approximate “rule of thumb” is to allow for a collector area equal to half the surface area
of the pool.
Proximity to pool –The panels need to be as close to the pool as possible, although longer pipe
runs are possible but may need an additional pump.
Orientation –Ideally the collectors should be mounted on a flat or north-facing roof, or an
elevated ground mounted rack, facing north. Where necessary, East facing or West facing roofs can
be used (in that order of preference). Then the system has to be sized to compensate for ‘lost’ time
in the morning (west), and an afternoon (east)
Tilt –Be sure the planned position of the collector panels allows for them to drain naturally when
the pool pump shuts off.
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Preparing a schematic diagram
Once you have decided on the location for the panels, it is useful to prepare a schematic diagram of
the system you wish to construct, taking into account the collectors sizes available.
1. Fill in a “Site layout sheet”. This will help you decide on the best system for your site.
2. Prepare a schematic drawing of the installation area. Include the proposed location of the feed
and return lines.
3. Use the panel dimensions in the table below to sketch the system you will construct.
Tip: Roof areas often give the impression of being bigger than they really are, so be sure to actually
measure the available area before making your drawing.
Note: Where possible construct your system using panels of the same length (if possible the largest
length).
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Sample system layout
Figure 3.1: Sample collector system
1. Feed line to the farthest point from pump house and lowest point on system.
2. PVC pipe connecting across a large obstruction
3.Flat roof
4.Return line as short as possible.
Note: Full details of how to connect the supply and return pipes are given in Chapter 7.
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Mounting racks
Where there is no roof space, or not enough for all the collectors, you may need to construct a rack
to mount some or all of the Heliocol panels. The rack must provide a stable base for the panels to
be secured to.
When designing a mounting rack the following considerations should be taken into account:
The tilt of the rack must be sufficient to allow the collectors to drain naturally when the pool
pump shuts off.
When calculating the area for the rack, take into account that collectors expand and contract
due to temperature changes under normal working conditions. Allow 5cm extra length per
collector.
Allow room on the rack for the supply and return plumbing, and plumbing between collectors
and banks.
The mounting rack must be stable, and able to support the weight of the collectors when filled
with water, which is up to 5kg/m2.
Figure 3.2: Sample mounting rack
Note: Whenever unglazed solar collectors are installed on a rack, a substrate should be mounted on
the rack prior to mounting the panel. This eliminates heat loss and stress created by wind blowing on
the backside of the rack.
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4 Parts and tools
Once you know the layout of your solar collector system, and how many panels/modules you
require, this chapter will help you calculate which Heliocol and other fittings you will need to
complete your installation.
This chapter deals with the following three categories:
Heliocol fittings and accessories
Other fittings
Tools
Description Picture Dimensional Data
PPC Set
(Plastic Panel Connector)
Top, Bottom, Clip
& O-ring
C.P.V.C
Adaptor
End Cap
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Heliocol fittings and accessories
This section summarizes the four basic types of connection to and between Heliocol panels, using
Heliocol fittings.
Connecting between panels
To connect a panel to a panel, you need 2 PPC connector sets.
Each PPC consists of a clamp top and bottom, a rubber gasket, and a latch, one to connect the
upper manifolds and one to connect the lower manifolds.
Figure 4.1: PPC (Plastic Panel Connector) set
Ends of a bank
When all the panels in a row are connected together you will have four open ends. Two of these
will be connected to the supply and return plumbing, and the other two will usually be blocked
with end caps.
For each bank you will
require:
2 End Caps, and
2 CPVC Adapters
Figure 4.2: Ends of a bank
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Securing panels to the roof
Panels are secured to the roof using 16mm Polypropylene Strapping. The standard installed
requires 2 per panel on the top manifold.
On a tiled roof the strapping can be attached by a variety of accepted methods:
Directly around the wooden battens.
By looping the strapping through a piece of 50mm PVC piping and inserting the system up
and under the tile such that it is trapped in position at the head of the tile.
It is advisable to coat the exposed strapping after the installation with a proprietary acrylic
roof paint for additional UV protection.
Where necessary using anchor bolts and wide washers directly into the ridge tile. This
method requires the application of a suitable waterproofing system over the washer / nut on
display.
On an IBR / Harvey Tile Roof the best method is to use a wide shoulder Pop Rivet followed by
waterproofing.
Heliocol fittings summary
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5 Hydraulics
This chapter deals with the hydraulics that needs to be considered before installation.
Panel configurations
Before you can start constructing the system you have designed, you must consider how the banks
will be connected together. You must also take into account the maximum number of panels
allowed per bank, as shown below.
These maximums may be exceeded if there is
high-pressure flow or substantial back pressure
on the system that will force adequate flow
through every panel. In other cases you should
divide the bank into two using one of the other
configurations.
Banks in parallel can also be used for smaller
installations, when space is limited.
Guidelines for residential installations
Panel Layout
Flow rate
Single Bank:
It is not recommended to install more than 6
panels for this layout.
120 lit/min
Bank in Series:
When installing more than 6 panels, it is
advisable to use the split in series bank system.
This will allow you to control the flow rate
more efficiently.
Remember that the largest bank is always
installed first before the split then smaller
bank.
(A) 4 Bank –split –3 Bank
(B) 4 Bank –split –4 Bank
(C) 5 Bank –split –4 Bank
(A)
80 lit/min
(B)
80 lit/min
(C)
100 lit/min
These configurations are calculated around availability from a pump in a residential configuration
of ± 120 lit/m. Maximum subject to available flow in 10 in 1 bank but this is usually in dedicated
industrial / commercial set ups.
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Basic plumbing & arrays layouts
SINGLE BANK WITH OBSTACLE
Split around the obstacle or over the parapet or split level
roofs
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Plumbing
Water inlet /outlet
Inlets are always connected to a lower end of the bank; outlets to the upper corner diagonally
opposite.
Using the “Reverse return” (Tichelmann) method would ensurebalanced flow in all collector
banks.
Pipe diameter
It is important that all plumbing connected to the system uses a diameter of PVC pipe appropriate to the
size of your solar array. Too narrow a pipe will unnecessarily restrict water flow to the panels. Use the
following as a guide:
For larger flow rates you may need to operate alternative series-plumbing techniques.
Plumbing runs
Plumbing runs should be as short as possible, especially the “Hot Return” pipe (to minimize heat loss).
Pipes should be supported every meter or so, to prevent sagging and movement.
Tip: Since 90° elbow fittings greatly restrict water flow, use as few of these as possible. In some
cases two 45° fittings can be used in place of a 90° fitting.
Tip: When clamping pipes that run across the roof use clamps that allow 1cm for expansion of the
pipe in hot weather.
Tip: When clamping pipes on the side of a building use clamps with a diameter equal to the pipe
diameter, to prevent vibration and to assure a professional looking installation.
Balanced flow
If you install a split system, such as one of those shown in former page, it is essential that the piping is
connected exactly as shown, to ensure equal water flow through both banks of panels. Water follows the
path of least resistance, so if one plumbing run is shorter, more water will flow through it than through the
longer one. This should also be kept in mind when designing a panel layout different to those shown.
For larger, more complicated congurations “balancing valves” may be necessary to maintain equal water
pressure in all parts of the system.
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Pump power
The power of the swimming pool filtration pump must be adequate to supply the Heliocol system
with the minimum recommended flow rate necessary for the number of panels being installed.
These recommended rates in litres per minute are:
For example: If you were installing ten HC-40 (4’x10.5’) panels, your pump would have to be able
to deliver 120 liters/m to the solar array. These recommended flow rates may be exceeded by as
much as 100% without any detrimental impact on the performance of the system. The existing pool
filtration pump is usually adequate for circulating the water through the solar system.
Generally, a x 0.75 kW pump is sufficient for a standard private pool solar system, unless there is
an unusually long pipe run, a high roof, or a large number of panels. If you are not sure what your
pump ow rate is, consult your Heliocol Representative or Pump Manufacturer for the pump’s
flow characteristics.
Booster Pumps
Under extreme requirements, e.g. of long runs and / or high lifts of 7m or greater there is no
alternative but to install a booster pump in the solar delivery piping.
NOTES:
The booster pump should be normally 1 size smaller or the same size as the pump on the filtration
unit. NEVER BIGGER.
The two pumps should be electrically interlocked to ensure that the booster can only operate when
there is water exiting the filtration system. If not the booster can run dry and fail.
To enable the solar to be switched off when not required install an isolating electrical switch on the
electrical feed from the timer to the booster pump.
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Automatic drainage
The panels and the PVC pipe must be installed so that the water drains out of them when the pool
pump shuts off. This is especially important in areas where freezing occurs.
To assist drainage a vacuum breaker is installed on the solar feed line above the 2-way valve, as
shown in the drawing on page 19.
Important: Heliocol Solar Pool Panels are warranted against internal freezing on condition that they
are installed to allow for automatic draining.
Compensating for lack of automatic drainage
If, due to unusual roof design or pool equipment location, it is not possible to achieve complete
automatic drainage, manual drain down valves must be installed in appropriate places in the
plumbing, or at the end of the bottom (feed) header.
Instead of installing an End Cap at the end of the header, place a CPVC and pipe to a ball valve for
manual drain. These valves should be opened when shutting down the system for the winter
months or when outdoor temperatures approach freezing point.
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6 Installation
This chapter describes four basic installation processes:
Connecting panels together
Connecting panels across an obstruction
Securing panels to the roof (sloping or flat)
Gluing PVC joints
Connecting panels together
1
Lay the two panels side by side with the panel
spacer bars facing down. Place a PPC connector
(top, bottom, gasket and latch) at both ends where
the headers meet.
2
Clean the groove of both headers and dry them.
3
Insert the gasket (420211) into the groove of one
of the headers.
4 Connect the two headers by inserting the rubber
gasket (420211) into the opposite header groove
and fitting the ends of both headers into the plastic
panel clamp.
Important: Make sure that the gasket sits
snugly in the grooves of both headers, and is
not squashed or pinched between the
headers, as this could result in leaking.
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5
Place the bottom half of the plastic panel clamp
under the header end with the larger, flat portion
facing away from the panel and the male “hook”
aligned with the riser pipes.
THIS IS MOST IMPORTANT.
Any other position will result in damage to the
panel, as the other parts of the PPC are too
wide to fit between the risers.
6
Interlock the tab in the top half of the clamp with
the hole in the bottom half (120210B), swing the
top half (120210T) round over the headers, then
lock the two halves of the clamp together using
the latch (120211) (do this by sliding the large end
of latch over small end of the PPC assembly.)
7+8
Use channel lock pliers to tighten the latch grip by squeezing it with moderate force until it
seats flush so it cannot slide out of its position.
9 The headers are now connected.
10 Repeat the procedure to connect the headers at
the other end of the panels.
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Bypassing a small obstruction
Small obstructions can sometimes be bypassed simply by unclipping some risers from the spacer
bars and spreading them to either side of the obstruction.
Figure 6.1: Bypassing a small obstruction
Important: If the obstruction is between one of the headers and the adjacent spacer bar this method
must not be used, as it might cause a riser to become detached from the header. The Plastic Magen
Warranty does not cover incorrect installation of this type.
Connecting across a large obstruction
For obstructions more than 15cm wide, or less than 30cm from one of the headers, you need to
circumvent the obstacle using extension pipes between the manifolds.
Figure 6.2: Connecting across an obstruction
Therefore, when connecting two panels/modules together across a large obstacle you need:
4 PPC sets
4 CPVC adaptors
2 lengths of PVC pipe cut to the required length.
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